Chevrolet Sonic Repair Manual: Gears Cleaning and Inspection (Gen 2)

Chevrolet Sonic Repair Manual / Powertrain / Transmission/Transaxle / Manual / General / Gears Cleaning and Inspection (Gen 2)

Gears

Warning:

Wear safety glasses to avoid injury when using compressed air or any cleaning solvent. Bodily injury may occur if fumes are inhaled or if skin is exposed to chemicals.

Clean the following gears in a suitable solvent and air dry all the parts.

1st Gear (1)
2nd Gear Assembly (4)
3rd Gear Assembly (3)
4th Gear Assembly (2)
5th Gear Assembly - Driven (5)
5th Gear - Driving (6)

Inspect the gear tooth surfaces on all the gears for the following conditions:

Cracks
Pitting
Nicks
Chipped gear teeth
High spots ?small shiny spots on the gear teeth mating surfaces

Input Shaft

Clean the input shaft (1) in a suitable solvent.
Clean and air dry the oil gallery.
Inspect the input shaft bearing surfaces for the following conditions:

Wear
Lack of lubricant
Debris embedded in the oil grooves
Brinelling

Inspect the input shaft splines for wear or damage.

Replace the input shaft if any of the above conditions are found.

Main Shaft

Clean the main shaft (1) in a suitable solvent.
Clean and air dry the oil gallery.
Inspect the main shaft bearing surfaces for the following conditions:

Wear
Lack of lubricant
Debris embedded in the oil grooves
Brinelling

Inspect the main shaft splines for wear or damage.

Replace the main shaft if any of the above conditions are found.

Reverse Gears and Shaft

Clean the reverse spur gear (1), reverse helical gear (2),

Clean the reverse spur gear (1), reverse helical gear (2), and shaft (5) in a suitable solvent and air dry all the parts.
Inspect the reverse spur gear bushings (4) and reverse helical gear bushings (3) for the following conditions:

Excessive wear
Scoring
Pitting

Replace the reverse gears if the bushings are faulty.

Inspect the reverse gear shaft for the following conditions:

Excessive wear
Scoring
Pitting

Replace the reverse gear shaft if it is faulty.

Gears Cleaning and Inspection (Gen 1)

Gears Warning: Wear safety glasses to avoid injury when using compressed air or any cleaning solvent. Bodily injury may occur if fumes are inhaled or if skin is exp ...

Input Shaft Assemble

Special Tools J-840733 Driver For equivalent regional tools, refer to Special Tools. Note: Ensure the input shaft rear bearing retaining ring (2) is placed on the input s ...

Other materials:

Child Restraint Systems
Rear-Facing Infant Seat A rear-facing infant seat provides restraint with the seating surface against the back of the infant. The harness system holds the infant in place and, in a crash, acts to keep the infant positioned in the restraint. Forward-Facing Child Seat A forward-facing chil ...

Halogen Bulb Warning
Warning: Halogen bulbs contain gas under pressure. Handling a bulb improperly could cause it to shatter into flying glass fragments. To help avoid personal injury: Turn off the lamp switch and allow the bulb to cool before changing the bulb. Leave the lamp switch OFF until th ...

Drivetrain and Front Suspension Frame Skid Plate Replacement
Removal Procedure Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle. Remove the mounting bolts (1) for the front suspension frame skid plate. Remove the front suspension frame skid plate (2). Installation Procedure ...

0.0056